Masonry veneer hanger and spacer

ABSTRACT

A plastic hanger for attaching a piece of veneer to a surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

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REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON COMPACT DISC AND AN INCORPORATION-BY-REFERENCE OF THE MATERIAL ON THE COMPACT DISC

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STATEMENT REGARDING PRIOR DISCLOSURES BY AN INVENTOR OR JOINT INVENTOR

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BACKGROUND OF THE INVENTION

The present invention relates to apparatuses for attaching decorative coverings to a wall. Stone panel wall construction devices and techniques. Stone masonry can be expensive because installing it can be labor intensive requiring craftsman with specialized knowledge and experience and the materials may be costly. Traditional stone masonry also may not have insulating properties as advantageous as other materials. Remodeling to use traditional stone masonry on an existing structure can require substantial demolition and re-work.

Conventional veneer is usually installed using one of three techniques. The first technique involves using mortar. In a mortar technique, the surface to which the veneer is to be installed has a rough face. This often takes the form of an exposed fibrous grid pattern resembling a grid exposed on the surface. A wet mortar is then applied on the face of the surface and the veneer is applied on/into the mortar. Once the mortar cures, the veneer is permanently attached to the surface. The second technique involves bolting veneer to a surface. Anchors may be installed in the surface to which the veneer is to be attached. Bolts or screws are then used to attach the veneer to the anchors. Alternatively, for certain surfaces, a separate anchor may not be required and the veneer may be bolted or screwed directly to the surface or features behind the surface (such as studs). The third technique includes a metal hangar or bracket being attached to the veneer. This hanger may be attached to the veneer as a part of the manufacturing process, or it may be attached as part of the installation process. The hanger generally has a flat face with one or more holes through which a nail or screw may pass to attach the hanger, and indirectly the veneer, to the surface.

DESCRIPTION OF RELATED ART INCLUDING INFORMATION DISCLOSED UNDER 37 CFR 1.97 AND 37 CFR 1.98

Not Applicable

BRIEF SUMMARY OF THE INVENTION

A plastic device for attaching faux stone to a surface.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 shows a front perspective view of a hanger of the present invention.

FIG. 2 shows a rear perspective view of a hanger of the present invention.

FIG. 3 shows a bottom perspective view of a hanger of the present invention.

FIG. 4 shows a side edge perspective view of a hanger of the present invention.

FIG. 5 shows a side edge perspective view of an alternative embodiment of a hanger of the present invention.

FIG. 6 shows a rear perspective view of a hanger of an alternative embodiment of a hanger the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Plastics are a wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. Plasticity is ability of certain solids to flow or to change shape permanently when subjected to stresses of intermediate magnitude between those producing temporary deformation, or elastic behavior, and those causing failure of the material, or rupture (see yield point). The plasticity of plastics makes it possible for plastics to be molded, extruded or pressed into solid objects of various shapes. This adaptability of plastics, plus a wide range of other properties, such as their generally being lightweight, durable, flexible, and inexpensive to produce, has led to the widespread use of plastics. Plastics are typically made through human industrial systems. Most modern plastics are derived from fossil fuel-based chemicals like natural gas or petroleum though they may also be made from renewable materials, such as corn or cotton derivatives.

One can control a number of plastic attributes by altering their chemical composition, additives, coatings, and manufacturing process. Some of the attributes include chemical resistance, dielectric strength, flexural strength, light transmission, heat deflection temperature, impact energy, notch sensitivity, maximum continuous operating temperature, Rockwell hardness, tensile strength, and UV resistance.

Heat deflection temperature is the temperature at which a material deforms under a specified load. The temperature is increased at 2° C. or 35.6° F./min until the specimen deflects 0.25 mm/0.01 in. The deflection temperature test results are a useful measure of relative service temperature for a polymer when used in load-bearing parts. However, the deflection temperature test is a short-term test and is generally not used alone for product design. For purpose of this application, including claims, heat deflection is measured with the specific load being the weight of the piece of veneer attached to the hanger. ASTM D648-18 defines the standard test method for deflection temperature of plastics under flexural load in the edgewise position.

UV resistance is defined as the ability of a material to resist ultra violet (UV) light or sunlight. UV light, or sunlight, will cause non-resistant materials and surfaces to fade or discolor. A UV accelerated weathering tester reproduces the damage caused by sunlight that occurs over months or years outdoors in a few days or weeks. UV resistance is measured using the following method. A sample is placed 20 cm from a standard UV-lamp (OSRAM Ultra-Vitalux, high pressure ultraviolet lamp, 300 W, 220 V) which reproduces the solar spectrum. The sample is exposed, to the light of this lamp in a conditioned cabinet (55° C., 85% RH) for 24 h. The color change of the sample is then measured of the samples in units of deltaE. One deltaE is defined as the minimum color difference perceivable by human eye. For purposes of this application, including claims, a sample is considered UV resistant if after aging the material presents a value of this parameter less than or equal to 2 deltaE.

The present invention is a hanger 100 for installing artificial stone veneer on a wall. The hanger 100 comprises a body member 114. In a preferred embodiment, the body member is a generally a rectangular prism which is thin relative to its width and height. In certain embodiments, the body member 114 extends above, below, or to either or both sides of a piece of artificial stone veneer to which the veneer is attached.

In a preferred embodiment, the front of the body member 114 contains one or more veneer attachment protrusion(s) 108 which extend away from the body member 114. The veneer attachment protrusion(s) 108 is/are configured to be attached to a piece of artificial stone veneer. In a preferred embodiment, the veneer attachment protrusion(s) 108 is/are rounded with open centers, approximating the shape of a d-ring. In an alternative embodiment, the veneer attachment protrusion(s) do not have an opening but rather are thicker at some portion further from the body member 114 than nearer the body member 114. In another alternative embodiment, the veneer attachment protrusion(s) are curved in a corkscrew shape. In other embodiments, the veneer attachment protrusion(s) are other shapes which resist the separation of the veneer from the body member 114 when the veneer has adhered to the veneer attachment protrusion(s) 108. In certain embodiments, witness holes 204 are located immediately behind veneer attachment protrusion(s) 108. In a preferred embodiment, the veneer attachment protrusion(s) are comprised of plastic. In an alternative embodiment, the veneer attachment protrusion(s) are comprised of a material other than plastic, such as metal. In this alternative, the veneer attachment means may be fasteners such as masonry anchors which are connected through the body into the finished veneer. The veneer attachment means may also be anchors, such as i-bolts, which are molded into the body and integral to the body and are then later attached to the veneer, either before or after it is cured (if necessary).

In a preferred embodiment, the body member 114 contains one or more holes 110, referred to as witness holes, passing through from front to back. In a preferred embodiment, the witness holes 110 align with the veneer attachment protrusion(s) 108. The witness holes 110 are configured to aid in the installation of the hanger 100 into the veneer. In a preferred process, a mold is filled with liquid veneer material to approximately a predefined level. The hanger 100 is then placed over the mold with the veneer attachment protrusion(s) 108 facing the open top of the mold containing the veneer material. The hanger 100 is then pressed into the veneer material. The depth of the veneer attachment protrusion(s) 108 in the veneer material is visible through the witness hole(s) 110. The fill volume of the veneer material can very to a degree as long as it is sufficient for the veneer material to cover the end(s) of the veneer attachment protrusion(s) 108 as the veneer material cures.

In a preferred embodiment, the hanger 100 is further configured with alignment features 106. These alignment features (mold alignment features) 106 are configured to align with features of the mold when the hanger 100 is installed in the veneer material. In an alternative embodiment, the alignment features 106 are configured to align with features of a jig and/or other member which holds the veneer mold. The alignment features 106 facilitate the consistent placement of the hanger in relation to the veneer pieces. In an alternative embodiment, the hanger is configured with alignment features (installation alignment features) 106 configured to indicate placement of an additional course of veneer to aid in consistent spacing between courses of veneer. The mold alignment features 106 and installation alignment features 106 may be the same or may be distinct. In a preferred embodiment, the alignment features are formed into the plastic hanger.

In a preferred embodiment, the back face of the body member 114 is configured with one or more spacing member(s) 202. The spacing member(s) 202 is/are configured to, when the hanger 100 is installed on a surface, prevent the body 114 of the hanger 100 from directly contacting the surface. By preventing the body 114 of the hanger 100 from resting against the surface, a gap is thereby formed which allows water to easily drain from between the veneer and surface. The gap further allows air to flow between the surface and the veneer drying the space thereby mitigating the risk of mold and freezing damage. In a preferred embodiment, the spacing member(s) 202 is/are approximately circular cylinders. In a preferred variation of this preferred embodiment, the spacing members 202 are at least partially hollow.

In certain embodiments, the hanger further comprises one or more surface attachment member(s) 104. The surface attachment member(s) 104 is/are attached to the body member 114. In a preferred embodiment, the surface attachment member(s) 104 have a front and back. In a preferred embodiment, the back of the surface attachment member(s) 104 lies in approximately the same plane as the portion of the spacing member(s) 202 configured to contact the surface. In a preferred embodiment, the surface attachment members 104 are further configured with marks 102 which indicate one or more preferred attachment location points where it is recommended the surface attachment member 104 should be attached to the surface. In a preferred embodiment, the surface attachment member(s) 104 do not contain one or more hole(s) for one or more nails or screws to pass through when attaching the surface attachment member(s) 104 to the surface. In a preferred embodiment, the material from which the hanger 100 is constructed is selected such that a brad, staple, screw, nail, or other attachment means of small to moderate size does not split the hanger 100 when inserted through the surface attachment member(s) 104 of the hanger 100. In certain embodiments, features of the surface attachment member(s) 104 are configured to interact with features of the body member 114 to assure consistent spacing between adjacent courses of facade.

In a preferred embodiment, the surface attachment member is a strip 602 running approximately the width of the body member. Because the strip does not have to perforated (contain an aperture) at the location where it is to be attached the hanger can be attached anywhere along the width of the hangar. In a preferred method, the hanger is placed against the surface and the location of the surface attachment fastener can be selected anywhere along the width of the strip, such as into a stud.

In embodiments where the body member 114 extends beyond the piece of veneer to which the hanger is attached, the portion of the body member which extends beyond the piece of veneer may serve as a spacer or support for an adjacent piece of veneer.

If suspended from the top, and not adequately supported along the height of the veneer, a course of veneer may tip down with the bottom closer to the surface and the top further from the surface than desired. This is most likely to occur with the bottom course. In order to support the veneer toward the bottom, a hanger 100 may be configured without one or more surface attachment members 104 such that the spacing members 202 provide support to aid in keeping the veneer vertical.

In certain embodiments, the thickness of the surface attachment member(s) 104 is reduced in the area of the hanger 100 intended for the attachment means. When the thickness of the surface attachment member 104 is reduced, the reduction in thickness is selected such that the top of the attachment means does not extend beyond the surface of the adjacent surface attachment means when installed.

In certain embodiments, the hanger 100 has additional holes 110 in the body, surface attachment member, and/or spacing member(s). These additional holes 110 reduce the amount of material in the hanger reducing materials cost and weight. These additional holes 110, in whole or in part, may also function as alignment features.

In a preferred process of using the hanger 100, an artificial stone mold is placed on a surface with the desired amount of slope/tilt (or lack thereof). This mold may replicate the features of one or more pieces of stone. The mold is then filled with liquid artificial stone material. A hanger 100 is then aligned, using alignment features 106 on the hanger 100, with one or more features of the mold. The hanger 100 is then pressed into the mold to a desired depth. The desired depth may be controlled by the mold, by a jig, or other means to achieve a consistent and desired distance between the bottom of the mold and back of the hanger 100. In an alternative process, the hanger 100 is positioned and then the mold is filled with liquid artificial stone material. The liquid artificial stone material is then allowed to cure.

In a preferred process, the hanger 100 is used to install artificial stone veneer on a surface in the following way. If desired, the surface is marked with one or more horizontal marks to allow alignment features 106 of the hangers 100 or veneer sections to be aligned on those marks. Starting at the bottom of the surface to which the veneer is to be installed, a first piece of veneer is placed against the surface. A staple gun is placed against the surface attachment member 104. The staple gun is activated causing a staple to be inserted through the surface attachment member 104 into the surface. In an alternative embodiment, a nail, brad, or screw is used in place of a staple. Various means used to secure the surface attachment member 104 to the surface are within the scope of the present invention. A second piece of veneer is placed beside the first of veneer at approximately the same height where the height is set using alignment features 106 of the hanger 100 and marks on the surface. Additional pieces of veneer are attached to the surface to complete a first (bottom) course. A second course is then installed further up the surface with the desired separation, or lack there of, between the first (bottom) and second courses. In a preferred method, the pieces of veneer in the second course is horizontally offset some amount from the pieces of veneer in the first course. Features of the veneer sections may cause them to interlock at a particular offset with veneer sections above and below a particular piece of veneer.

In certain embodiments, the hangers 100 of adjacent courses are configured to interlock. In this embodiment, the top of the hanger 100 is configured with a feature to accept features from a later-installed hanger 100 from the next higher course of veneer. In a preferred embodiment, this feature is a space between the body of the hanger and the surface when the hanger is attached to the surface. In a preferred embodiment the feature of a later-installed hanger 100 from the next higher course of veneer is an extension 116 which is configured to fit between the body 114 of the hanger 100 and the surface. In alternative embodiments of this embodiment, the hangers 100 interlock horizontally instead of, or addition to, vertically. Interlocking features may be provided by a plurality of hanger pieces when desired.

For purposes of this application, including claims, the following definitions are provided. “Substantially solid” means a surface which is rigid and which prevents the passage of articles the apparatus is designed to store and dispense. “Plurality” means one or more. “Series” means one or more. “Veneer” means stone, aggregate veneer, tile, wood, and any other relatively thin material mounted on a surface for decorative, aesthetic, or other non-structural purpose. A “push-through fastener” means a fastener, other than a self-tapping screw, specifically including bolts, nails, staples, brads, and screws. 

1. An apparatus for attaching veneer to a surface comprising: A) means for attaching said apparatus to a plurality of pieces of veneer, B) means for accepting a fastener to attach said apparatus to a surface comprising: I) a region of the apparatus configured to permit a fastener to be installed through the apparatus without requiring an aperture in the apparatus, and C) said apparatus is comprised, at least partially, of a plastic having a softening temperature not less than 100 degrees Fahrenheit.
 2. The apparatus of claim 1 wherein: A) said means for attaching said apparatus to a plurality of pieces of veneer are integral to said apparatus.
 3. The apparatus of claim 2 wherein: A) said means for attaching said apparatus to a plurality of pieces of veneer are comprised of a material other than plastic.
 4. The apparatus of claim 3 wherein: A) said means for attaching said apparatus to a plurality of pieces of veneer are comprised of metal.
 5. The apparatus of claim 1 wherein: A) said means for attaching said apparatus to a plurality of pieces of veneer are comprised of a material other than plastic.
 6. The apparatus of claim 5 wherein: A) said means for attaching said apparatus to a plurality of pieces of veneer are comprised of metal.
 7. The apparatus of claim 1 wherein: A) the plastic of the apparatus is UV resistant.
 8. The apparatus of claim 1 wherein: A) the apparatus is comprised, at least partially, of injection-molded plastic.
 9. The apparatus of claim 1 wherein: A) the apparatus is comprised entirely of plastic.
 10. The apparatus of claim 9 wherein: A) the apparatus is comprised entirely of injection-molded plastic.
 11. An apparatus for attaching veneer to a surface comprising: A) means for attaching said apparatus to a plurality of pieces of veneer, B) means for accepting a fastener to attach said apparatus to a surface comprising: I) a region of the apparatus configured to permit a push-through fastener to be installed through the apparatus without requiring an aperture in the apparatus, and C) said apparatus is comprised, at least partially, of a plastic having a softening temperature not less than 100 degrees Fahrenheit. 